Cold extrusion technology has advanced and expanded over the past few years to a point where much larger, more dense and complex parts are being successfully produced by the millions. Innovations in blank preparation and new approaches to tooling have been highly instrumental in this breakthrough, which can solve many problems in our waste-conscious, energy-poor society. Key elements that have created the new and greatly enlarged potential for cold extrusion are discussed. Case histories of complex parts weighing up to 5-1/2 lbs. that have been converted from metal cutting to cold extrusion are fully documented with data on raw material and machining comparisons.